Mechanically Actuated Control-Arm Regenerative Output System (MACROS)

ABSTRACT

A multiple mechanically actuated regenerative output system having a rack gear that moves linearly between a first position and a second position to a shaft of an alternator.

RELATED APPLICATIONS

This application is a continuation in part of U.S. Ser. No. 16/818,495filed on Mar. 14, 2020, which claims priority to U.S. ProvisionalApplication Ser. No. 62/817,941 filed on Mar. 13, 2019, both of whichare incorporated herein by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH & DEVELOPMENT

Not applicable.

INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

Not applicable.

BACKGROUND OF THE INVENTION

10 years ago, the first Kinetic Energy Recovery System (KERS) wasdesigned. It harnessed the kinetic energy of a slowing car to produceelectrical energy (i.e. energy regeneration), whereas a non-KERSequipped car would expend that energy as heat during braking. It wasused extensively in Formula 1 and has recently been implemented in somehigh-end production automobiles. Several attempts were also made atdeveloping a KERS that utilized the kinetic energy of suspension ratherthan braking to regenerate electrical energy (hydraulically actuated,electromagnetically actuated, mechanically actuated), but most have beenabandoned due to the cost of development and a lack of manufacturabilityresulting from complex design schemes.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, the present invention provides a mechanicallyactuated control-arm regenerative output system, or MACROS, thatharnesses the kinetic energy from a suspension system that wouldotherwise be expended as heat to produce electrical energy viamechanical actuation. This electrical energy can be used to powerapplicable on-board systems.

Other embodiments of the present invention have applicability to thefollowing industries either as an aftermarket installation (bolt-on; nomodification) or manufacturer installation: automotive to increase therange of electric cars or increase fuel economy; agriculture equipmentto improve fuel efficiency as well as to power auxiliary equipment;defense to increase the range of equipment as well as power auxiliarysystems; space exploration to increase fuel efficiency and to powerauxiliary systems; and over the road freight to increase fuelefficiency.

In other embodiments, the present invention provides a multiplemechanically actuated regenerative output system comprising a rack gearthat moves linearly between a first position and a second position, andwhen the rack gear moves towards the first position a shaft of analternator is rotated.

In other embodiments, the present invention provides a system forgenerating a current in a moving piece of equipment comprising a rackgear connected to a pinion gear; the pinion gear attached to afreewheeling hub; and the freewheeling hub is attached to a shaft of analternator.

In other embodiments, the present invention provides a method forgenerating a current using the movement of a piece of equipmentcomprising steps of: attaching a rack gear connected to a portion of thepiece of equipment that moves linearly causing the rack gear to movebetween a first position and a second position; when the rack gear movestowards the first position, a shaft of an alternator is rotated.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numeralsmay describe substantially similar components throughout the severalviews. Like numerals having different letter suffixes may representdifferent instances of substantially similar components. The drawingsillustrate generally, by way of example, but not by way of limitation, adetailed description of certain embodiments discussed in the presentdocument.

FIG. 1 is a perspective view of a first embodiment of the presentinvention.

FIG. 2 is an exploded view of the embodiment shown in FIG. 1 .

FIGS. 3A, 3B, 3C, 3D and 3E illustrate the operation of an embodiment ofthe present invention.

FIGS. 4A, 4B, 4C, 4D, 4E and 4F illustrate the operation of an alternateembodiment of the present invention.

FIG. 5A shows the component of another embodiment of the presentinvention.

FIG. 5B is an exploded view (left) of the ratchet-pawl mechanism of oneembodiment of the present invention (right).

DETAILED DESCRIPTION OF THE INVENTION

Detailed embodiments of the present invention are disclosed herein;however, it is to be understood that the disclosed embodiments aremerely exemplary of the invention, which may be embodied in variousforms. Therefore, specific structural and functional details disclosedherein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention in virtually any appropriately detailedmethod, structure or system. Further, the terms and phrases used hereinare not intended to be limiting, but rather to provide an understandabledescription of the invention.

In one embodiment, as shown in FIGS. 1-2 , mechanically actuatedcontrol-arm regenerative output system 100 includes rack gear 110 whichis attached to moving part 190 which may be a strut. Pinion gear 120,ratchet gear 130, freehub 140 and Permanent Magnet Alternator (PMA) 150are also provided and, in a preferred embodiment, these components arestationary.

In use, as a moving vehicle or piece of equipment encounters a surfacedeviation, such as a bump, a mechanical component of the suspensionsystem, such as part 190, will move as the deviation is encountered.This, in turn, will cause at least one of the suspension components tomove. This movement can be harnessed and converted into energy.

In one preferred embodiment, as shown in FIGS. 1 and 3A-3E, as acomponent moves, attached rack gear 110 is adapted to move from a firstposition 170 to a second position 175. As rack gear 110 moves toward thesecond position, it engages pinion gear 120 causing it to rotate. Aspinion gear rotates 120, ratchet gear 130 is engaged. Since the ratchetgear is connected to the PMA shaft 135, the shaft is rotated therebyspinning a magnetic rotor that generates a voltage.

As shown in FIGS. 3 d and 3E, once rack gear 110 reaches the secondposition 175 and travels back towards first position 170, it needs to doso without spinning the shaft in a direction opposite of the directionin which energy is created. To do this, ratchet gear 130 is adapted toslip allowing for the free spinning of the PMA shaft in a direction thatgenerates a current.

In another embodiment, the pinion gear is adapted to move in a directionopposite the spinning of the shaft during energy generation when therack gear returns to the first position. Thus, the ratchet gear is notengaged (i.e. it slips on the ratchet teeth) and therefore does notimpede the motion of the alternator rotor shaft.

In yet another preferred embodiment involving a moving vehicle, butwhich could be used in any application, the present invention works asshown in FIGS. 4A-4F. As first rack gear 410 a moves linearly as shownin FIG. 4C-4F, the engagement between first rack gear 410 a and piniongear 420A (Y1), causes pinion gear 420A (Y1), to rotate in a firstdirection. As further shown in FIG. 4D, the rotation of pinion gear 420A(Y1) is engaged and spins the shaft of the PMA. As shown in FIG. 4C,once the linear direction of rack gear 410 a reverses, it rotates piniongear 420A (Y1) in the opposite direction wherein it slips and does notspin the PMA. As shown in FIG. 4A, when second rack 410 b travels in adirection wherein 420A (Y1) slips, 420B (Y3) is engaged and spins 425(Y2) which is also engaged. Because the rotation of 425 (Y2) when it isengaged is the same as 420A (Y1) when it is engaged, 425 (Y2) spins thePMA while 420A (Y1) is slipping which, in turn, also rotates ratchetgear 425 (Y2) in the opposite direction. However, ratchet gear 425 (Y2)is designed to slip and not rotate the PMA shaft when traveling in thisdirection.

Thus, when the alternator shaft spins, a magnetic rotor is spun inside atightly wound stator coil thus producing an electromagnetic force (i.e.voltage). Because of gravity, what goes up must come down. Therefore,suspension displacement (and consequently, the displacement of yourcontrol-arm) is sinusoidal (alternates between positive and negativedisplacements).

While a ratcheting freewheeling system has been described above, theratchet gear is one of many freewheeling or overrunning clutchassemblies known to those of skill in the art that may be used with thepresent invention. What is important, is that when the freewheeling hubchanges direction, the shaft of the PMA is allowed to spin freelywithout interference in a direction that generates energy.

In yet other embodiments, multiple mechanically actuated control-armregenerative output systems may be used with a single piece ofequipment. This has particular application in agriculture and heavyequipment as well as motor vehicles.

In another embodiment, as shown in FIGS. 5A and SB, the components ofthe present invention include a two-step rack gear (1A) having two gearfaces 1B and 1C wherein face 1B is offset from 1C. Also provided iscompression-engagement pinion gear (2), compression-engagement freehubwith spring-loaded pawls (3), compression-engagement ratchet (4),return-engagement intermediate pinion gear (5), return-engagement piniongear (6), return-engagement freehub with spring-loaded pawls (7),return-engagement ratchet (8), alternator (9), and alternator shaft(10). 1 is to be attached to a suspension structure (such as a controlarm) and 2-10 are to be attached to a chassis structure, so as to bestationary relative to 1. 4 and 8 are threaded and locked onto 10 sothat any torque imparted to 4 or 8 is imparted to 10.

When the suspension compresses, 1 moves linearly upward. This motionresults in the clockwise rotation of 2 and 5. Because 2 is attached to aratchet (4) and pawl (3) mechanism that only engages in the clockwisedirection, torque is transmitted to 10 in the clockwise direction,thereby allowing 9 to produce electric current. At the same time, theclockwise rotation of 5 results in a counterclockwise rotation of 6.Because 6 is attached to a ratchet (8) and pawl (7) mechanism that onlyengages in the clockwise direction, torque is not transmitted to 10.This allows to continue rotating in the clockwise direction (asinfluenced by the torque imparted to the shaft by 2-4), thereby allowing9 to continue producing electric current.

When the suspension returns to equilibrium from a compressed state, 1moves linearly downward. This motion results in the counterclockwiserotation of 2 and 5. The counterclockwise rotation of 5 results in aclockwise rotation of 6. Because 6 is attached to a ratchet (8) and pawl(7) mechanism that only engages in the clockwise direction, torque istransmitted to 10 in the clockwise direction, thereby allowing 9 toproduce electric current. At the same time, because 2 is attached to aratchet (4) and pawl (3) mechanism that only engages in the clockwisedirection, torque is not transmitted to 10. This allows 10 to continuerotating in the clockwise direction (as influenced by the torqueimparted to the shaft by 5-8), thereby allowing 9 to continue producingelectric current

While the foregoing written description enables one of ordinary skill tomake and use what is considered presently to be the best mode thereof,those of ordinary skill will understand and appreciate the existence ofvariations, combinations, and equivalents of the specific embodiment,method, and examples herein. The disclosure should therefore not belimited by the above-described embodiments, methods, and examples, butby all embodiments and methods within the scope and spirit of thedisclosure.

What is claimed is:
 1. A multiple mechanically actuated regenerativeoutput system comprising: a first freewheeling hub connected to a firstrack gear that moves linearly between a first position and a secondposition; said first freewheeling hub attached to a shaft of analternator; when said first rack gear connected to said firstfreewheeling hub moves towards said first position, said shaft of saidalternator is rotated by said first freewheeling hub and when said firstrack moves away from said second position towards said first position,said shaft of said alternator is not rotated by said first freewheelinghub; a second freewheeling hub connected to a second rack gear thatmoves linearly between said first position and said second position;said second freewheeling hub connected to a third freewheeling hub, saidthird freewheeling hub attached to said shaft of said alternator; andwhen said second rack connected to said second freewheeling hub movesaway from said second position towards said first position, said shaftof said alternator is rotated by said third freewheeling hub and whensaid second rack gear moves towards said first position from said secondposition, said shaft of said alternator is not rotated by said thirdfreewheeling hub.
 2. The system of claim 1 wherein said firstfreewheeling hub is a ratchet gear.
 3. The system of claim 1 whereinsaid first freewheeling hub is a clutch.
 4. A method for generating acurrent using the movement of a piece of equipment comprising steps of:providing a first freewheeling hub connected to a rack gear that isattached to said equipment and moves linearly between a first positionand a second position; said first freewheeling hub attached to a shaftof an alternator; when said rack gear connected to said firstfreewheeling hub moves towards said first position, said shaft of saidalternator is rotated by said first freewheeling hub and when said rackmoves away from said second position towards said first position, saidshaft of said alternator is not rotated by said first freewheeling hub;a second freewheeling hub connected to a rack gear that is connected tosaid equipment and moves linearly between said first position and saidsecond position; said second freewheeling hub connected to a thirdfreewheeling hub, said third freewheeling hub attached to a shaft of analternator; and when said rack connected to said second freewheeling hubmoves away from said second position towards said first position, saidshaft of said alternator is rotated by said third freewheeling hub andwhen said rack gear moves towards said first position from said secondposition, said shaft of said alternator is not rotated by said thirdfreewheeling hub.
 5. The method of claim 4 wherein said firstfreewheeling hub is a ratchet gear.
 6. The method of claim 4 whereinsaid first freewheeling hub is a clutch.
 7. The method of claim number 4wherein said rack gear is connected to a pinion gear; said pinion gearconnected to a freewheeling hub; when said rack gear moves towards saidfirst position, said shaft of said alternator is rotated by saidfreewheeling hub which is rotated by said pinion gear; and when saidrack moves away from said second position towards said first position,said shaft of said alternator is not rotated by said freewheeling hubeven though said pinion gear rotates said freewheeling hub.
 8. Themethod of claim 7 wherein said freewheeling hub is a ratchet gear. 9.The system of claim 1 wherein said second freewheeling hub is a ratchetgear.
 10. The system of claim 1 wherein said second freewheeling hub isa clutch.
 11. The system of claim 4 wherein said second freewheeling hubis a ratchet gear.
 12. The system of claim 4 wherein said secondfreewheeling hub is a clutch.